Dampers at the main shift rod

ABSTRACT

A compound transmission shift mechanism is disclosed. The shift mechanism includes a plurality of gears configured on at least one transmission shaft with at least one synchronizer configured to engage at least two of the plurality of gears. The shift mechanism includes a control system configured to engage and position the synchronizer into alignment with the at least two of the plurality of gears. Additionally, the shift mechanism includes at least one damping assembly configured on the control system and operatively connected to the synchronizer.

TECHNICAL FIELD

The technical field is generally related to multi-rail shiftingmechanisms of manual compound transmissions, and particularly, a gearselection system within the manual compound transmission.

BACKGROUND

Manual compound transmissions are used for various vehicle applications.Such compound transmissions typically comprise a multiple speed mainsection containing a plurality of gears for various range and loadgearing configurations.

Manual compound transmissions are generally positioned within adriveline adjacent a primary drive unit with at least one rotating driveshaft. These compound transmissions generally include a shifter or gearselector that extends from the transmission for interaction with anoperator. The compound transmission may include a rotating and slidingassembly that is configured to engage a desired gear set when anoperator moves the shifter or gear selector. Specifically, in a manualcompound transmission an operator, through the gear selector, selects anappropriate gear by pushing or pulling the shift lever to a desiredshift gate. A rail selector fixed to the main shift rail is configuredto translate the movement of the shift lever to the shift forks. Therail selector is fixed to the main shift rail by a roll pin that extendsthrough a central location of the rail selector. The action on the shiftlever causes a set of shift rails to move at least one shift fork, whichcauses a shift collar to slide over the appropriate rotating gear tosynchronize and activate a desired gear range.

Shift quality is an important factor for manual compound transmissionswhen selecting the desired gear range. There are many factors affectingshift quality, such as, but not limited to shift force, notchness frombumps and detents, nibble, and precision of the rotating and slidingcomponents, such as, but not limited to end stop feel and lash. Nibblemay be defined as a form of partial clash following a successfulsynchronizing action. It may result from a speed differential generatedduring the period between indexing and final engagement of the teeth forthe desired gear. Unfortunately, the previously discussed factorsaffecting shift quality are typically transmitted directly through therotating components and shift rails, as the previous designs includedshift components that were fixed directly to the shift rail. Thesefactors are transmitted directly through the components, through theshift lever and ultimately to the operator.

The shift quality is important to provide the operator with theappropriate feedback through the shift lever indicating that thecompound transmission is engaged in the appropriate gear set whilepreventing a mis-shift or other misalignment that may potentially damageor shorten the life of the transmission. The shift quality is alsoimportant for preventing fatigue and possible injury to the operator asthe feedback carried through the shift lever may result in damage to theoperators hand, wrist, arm or shoulder.

Therefore, it is desirable to provide a manual compound transmissionsystem that allows for improved synchronization of the meshingcomponents, while providing an additional damping mechanism to improveshift quality and an operator's shifting experience, thereby providing asmooth end stop feel preventing operator fatigue and providing prolongedtransmission life.

SUMMARY

The present disclosure relates to shift quality for manual compoundtransmissions. Manual compound transmissions include a shift leverinterconnected with at least one shift rail for moving a shift rail,which engages a plurality of shift rings for engaging at least one gear.An exemplary shift mechanism may be configured to filter out or removeat least two well known phenomenon known as notchness created when theshift mechanism engages the forks and nibble created when the shift ringsynchronizes with the at least one gear, which both may be felt in theshift lever.

An exemplary shift mechanism may also be configured to provide a smoothend stop feel when the operator selects a specific gear. The shiftmechanism may include a shift rail configured with at least one railselector. The rail selector may be positioned longitudinally on theshift rail with at least one damping member configured on the shift railadjacent at least one of a leading edge of the rail selector andtrailing edge of the rail selector. The rail selector may be locked intoplace on the shift rail by any known method. Specifically, the railselector may be prevented from sliding for or aft on the main shift railwith at least one stop pin and at least one tab washer.

Additionally, the shift mechanism may include an improvedsynchronization feature to aid in the prevention of nibble during gearselection. The improved synchronization feature may include a springingmechanism a spring is retained on a shift rail with at least one snapring configured outboard of the spring. The shift mechanism may includea sliding sleeve that when moved aside it pushes, via a strut orpre-energizer, a blocker ring against a targeted gear. The blocker ringrotates (due to friction) till meeting the wall of a fixed hub windowwhen pushed against a gear cone. At this position engagement chamfersare aligned to the chamfers of the sliding sleeve where asynchronization phase starts with the chamfers indexed/aligned. Once thesynchronization is completed, the blocker ring and the sliding sleeveare meshed (via the chamfers). The shift mechanism releases the slidingsleeve for advancing toward the targeted gear. The sliding sleeve andgear cone spline hit each other and again the splines are meshed due tothe action of engagement chamfers and then the engagement is completed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view, not to scale, of a compound manualtransmission with the case partially torn away;

FIG. 2 is a perspective view of an exemplary shift rail damper systemfor a compound manual transmission;

FIG. 3 is a perspective view of an enlarged shift rail damper assemblyconfigured on a main shift rail;

FIG. 4 is an exploded perspective view of an exemplary shift rail dampersystem;

FIG. 5 is partial section view of an exemplary rotating assembly;

FIG. 6 illustrates an exploded view of an exemplary synchronizer for anexemplary manual compound transmission;

FIG. 7 illustrates a section view of an exemplary pre-energizer havingan angled roller element;

FIG. 8A illustrates a section view of an exemplary pre-energizer andsynchronizer in a neutral position;

FIG. 8B illustrates a section view of an exemplary pre-energizer andsynchronizer in a synchronizing position;

FIG. 8C illustrates a section view of an exemplary pre-energizer andsynchronizer in an engaged position;

FIG. 9 illustrates a top view of an exemplary synchronizer in a meshingposition;

FIG. 10 illustrates a top view of an exemplary synchronizer in apartially engaged position; and

FIG. 11 illustrates a top view of an exemplary synchronizer in anengaged position.

DETAILED DESCRIPTION

Referring now to the discussion that follows and also to the drawings,illustrative approaches to the disclosed systems and methods are shownin detail. Although the drawings represent some possible approaches, thedrawings are not necessarily to scale and certain features may beexaggerated, removed, or partially sectioned to better illustrate andexplain the present disclosure. Further, the descriptions set forthherein are not intended to be exhaustive or otherwise limit or restrictthe claims to the precise forms and configurations shown in the drawingsand disclosed in the following detailed description.

Reference in the specification to “an exemplary illustration” and“example” or similar language means that a particular feature,structure, or characteristic described in connection with the exemplaryapproach is included in at least one illustration. The appearances ofthe phrase “in an illustration” or similar type language in variousplaces in the specification are not necessarily all referring to thesame illustration or example.

According to various exemplary illustrations described herein, a systemand method are disclosed. Specifically, an exemplary shift mechanism fora compound manual transmission is disclosed. The compound manualtransmission includes an input shaft and an output shaft, the inputshaft may be configured to engage a prime mover (not shown), while theoutput shaft may include a yoke for engaging a drive member (not shown).The compound manual transmission includes a main shaft, a countershaftand a plurality of gears configured with in the transmission housing.The main shaft may be configured between the input shaft and the endyoke, which may be configured at a rear of the compound manualtransmission. The main shaft may include a first plurality of gearsconfigured about the main shaft and in rotative alignment with a secondplurality gears configured on the countershaft. The shafts and gears aretypically referred to as the rotating assembly.

A shift lever may extend from a control tower configured on a shift barhousing, which may be attached to an upper section of the compoundtransmission housing. The shift bar housing may be configured toposition at least one shift rail in proximity to the rotating assembly,thereby slidably connecting the shift lever and at least one shift forkto the rotating assembly. The at least one shift rail may be configuredwith at least one damping element for the reduction or elimination ofnotch, nibble or other issue that may create poor shift quality. Thedamping element may be in the form of a spring, a low friction bushing,linear ball bearing or other known damping element that may beconfigured on the at least one shift rail. The connection between theshift lever and the rotating assembly allows for an operator to select adesired gear set as the lever may be directly connected to the gearswithin the compound transmission. The at least one shift rail, discussedin greater detail below, may include a rail selector and the at leastone damping element configured on a main shift rail of the at least oneshift rail. Through movement of the at least one shift rail, the shiftfork may engage at least one synchronizer, discussed in greater detailbelow, for meshing the selected gear set, which helps to prolong thelife of the compound transmission and minimize nibble that may beassociated with gear changing.

The rotating assembly, which includes the input shaft, main shaft,countershaft and synchronizer, may be configured to transmit torque fromthe prime mover to the output yoke through the desired gear set. Themain shaft may include a plurality of splined teeth that may beconfigured to engage a fixed hub of the synchronizer and ultimately theplurality of gears on the counter shaft, which may be driven by theinput shaft. The synchronizer may include at least one gear flange, atleast one blocker or synchronizer ring, the fixed hub, a sliding sleeveand a pre-energizer component. The flange, blocker, ring and hub allinclude teeth or cogs cut into an outer diameter surface of each andthese teeth are configured to engage and mesh with corresponding teethor cogs that are cut into an inner diameter surface of the slidingsleeve. The teeth each have engagement chamfers that aid in thealignment with corresponding chamfers on the sliding sleeves teeth.Thus, in operation, when the chamfers are indexed/aligned, asynchronization phase starts. Additionally, the pre-energizer componentmay include at least one of a strut, a roller, a plunger and a spring.

When the sliding sleeve moves aside it pushes, via the strut orpre-energizer, the blocker ring against the targeted gear. When pushedagainst a desired gear cone, the blocker ring rotates (due to friction)until meeting a wall of the fixed hub. At this position, an engagementchamfer may be aligned to a chamfer configured on the teeth of thesliding sleeve. Thus, with the chamfers indexed/aligned, synchronizationstarts. Once completed, the synchronization, blocker ring and slidingsleeve are meshed (via chamfers), which releases the sliding sleeve foradvancing toward the gear. The sliding sleeve and gear cone spline hiteach other and again the splines are meshed due to the action ofengagement between the chamfers, thereby completing the engagement.Thus, in operation, and operator positions the shift lever to select apredetermined gear set. The gear selection occurs by maneuvering theshift lever to slide the main shift rail, thereby connecting the shiftrail with the synchronizer and ultimately the gears. The rail selectorprovides a linear force that pushes or pulls the shift fork, therebysliding at least a portion of the shift fork against an outer engagementgroove on the outer diameter of the sliding sleeve to synchronize andengage the desired gear set.

Referring to FIG. 1 a compound manual transmission 100 is illustrated.The transmission 100 may comprise an input shaft 110 and an output shaft112, the input shaft 110 may be configured to engage a prime mover (notshown), while the output shaft 112 may include a yoke 114 for engaging adriven member (not shown). The compound manual transmission 100,discussed in greater detail below, includes an output shaft main shaft116, a countershaft 118 and a plurality of gears 120, 122 configuredabout the shafts 116, 118. The main shaft 116 and the countershaft 118are configured within the transmission housing 124 between andengagement with the input shaft 110 configured to extend forward of thetransmission housing 124 and the end yoke 114 configured to extend aftof the transmission housing 124. The main shaft 116 may include a firstplurality of gears 120 configured about the main shaft 116 and rotatablyaligned with a second plurality of gears 122 configured on thecountershaft 118. The input shaft 110, the output shaft 112, the mainshaft 116 and the countershaft 118 may be supported by the housing 124through a plurality of bearings 126. The main shaft 116 may include atleast one synchronization unit or synchronizer 140 (discussed in greaterdetail below) for engaging a predetermined output speed.

With continued reference to FIG. 1, an upper housing portion 128 may beconfigured to receive a shift bar housing 130. Additionally, a controltower 132 extends from the shift bar housing 130 to a shift lever 134.The control tower 132 may include a cross joint with axial adjustmentelements to increase shift selection while reducing any free play in theshift lever 134. The shift bar housing 130 may be configured to retainand align a gear change control system 136. The control system 136 maybe configured to translate movement from the shift lever 134 to at leastone shift fork 138 to select a desired gear set from the plurality ofgears 120, 122 for determining the predetermined output. Additionally,the shift fork 138 may be configured to engage at least a portion thesynchronizer 140 for selecting the predetermined gear set, discussed ingreater detail below.

FIG. 2 illustrates a detail view of the control system 136, which mayinclude at least one main shift rail 210. The main shift rail 210 mayinclude a first end portion 212, a mid-portion 214 and a second endportion 216. As illustrated, the control system includes a plurality ofshift rails. Specifically, a second shift rail 218, a third shift rail220 and a fourth shift rail 222. However, this illustration is merely anexample and any number of shift rails may be used. Additionally, eachshift rail 216, 218, 220 may include a respective shift fork 138, 138′,138″, as will be discussed in greater detail below. The main shift rail210 may include an engagement mechanism 230 and a rail selector dampingassembly 260, which will be discussed in greater detail below.

The engagement mechanism 230 may be used for interconnecting the shiftlever 134 with the main shift rail 210. The engagement mechanism 230 maybe configured on either the main shift rail first end 212 or the mainshift rail second end 216 depending on the particular position of thecontrol tower 132. The engagement mechanism 230 may be configured toreceive an end of the shift lever 134 and may include at least oneadjustment mechanism 240. The at least one adjustment mechanism 240 maybe configured on at least one side of the engagement mechanism 230 toaid in minimizing or eliminating free play while improving shiftquality. Additionally, the control tower 132 may include a cross joint(not shown) to also help with increasing gear selection while reducingor eliminating the free play. The adjustment mechanism 240 may includeone of a spring biasing member or detent plunger 242 configured to biastravel of the engagement mechanism 230 to improve shift definition andreduce free play of the shift lever 134, and a bias plate 246 havinggrooves and channels replicating a bias pattern for shift lever travelallowing the engagement mechanism 230 to maintain a defined shiftpattern, which improves shift definition and reduces or eliminates freeplay.

Additionally, the detent plunger 242 may include a biasing member 248and a bushing 250. The biasing member 248 may be a spring, elastomer orother known biasing device configured between the detent plunger 242 andthe bushing 250 or other fixed point. It has been found that the lengthof the detent plunger 242 and a detent ramp 244 may improve snap-inshift, while reducing lever play. A snap-in shift means that instead ofthe drive to push the lever to complete the engagement, in some phasesof the shift the shift lever pushes the hand of the driver, as if thelever automatically completed the shift itself. The detent ramp 244 maybe configured having an indented center section with outwardly slopedramps, which are sloped at a predetermined angle of approximately 23° to26°, such that the ramps slope upward to the indented centered section,as illustrated in FIG. 2. However, it should be realized that other rampsizes and shapes may be used to provide a positive engagement with thedetent plunger 242. Through extensive testing it has been shown that thedetent plunger 242, may have a rounded protrusion that is configuredengage the indented center section of the detent ramp 244. Additionally,the detent plunger 242 may have a length of approximately 25 mm to 40 mmwith an optimum range of approximately 30 mm to 35 mm, which has shownto greatly reduce lever play to aid in reducing operator fatigue.

At least one of the main shift rail 210, the second shift rail 218, thethird shift rail 220 and the fourth shift rail 222 may be slidablyconfigured in the shift bar housing 130. The shift rails 210, 218, 220,222 may include at least one anti-friction element 224, which mayprovide additional improvements for snap-in while helping to reduce oreliminate the notchness when the rails 210, 218, 220, 222 slide in thehousing 130. The anti-friction element 224 may be, but is not limitedto, a lubricative coating (Teflon), a bushing, a linear ball bearing, aroller bearing or other known anti-friction mechanism. The main shiftrail 210 may be configured to receive at least one rail selector dampingassembly 260. As illustrated, a single rail selector damping assembly260 is configured substantially at the mid-portion 214 of the main shiftrail 210. However, the number and position of the rail selector dampingassembly 260 is not limited to a single assembly or to one specificarea. Thus, the rail selector damping assembly 260 may be configuredanywhere along the main shift rail 210, as required by a specific manualtransmission 100 design. As illustrated, the rail selector dampingassembly 260 includes at least one engagement portion 262 that isconfigured to engage at least one connection element 270 configuredadjacent to the shift rails 218, 220, 222. The engagement between theconnection element 270 and the engagement portion 262 allows the mainshift rail 210 to be operatively connected with at least one of thesecond shift rail 218, the third shift rail 220 and the fourth shiftrail 222.

The rail selector damping assembly 260 may be of any dimension and shapefitting within the foot print of the shift bar housing 130. The railselector damping assembly 260 may be configured to translate movementfrom the shift lever 134 through the main shift rail 210 and through theshift forks 138, 138′, 138″ to select a desired gear set. Additionally,the shift forks 138, 138′, 138″ may be configured to connect directly tothe respective shift rail 210, 218, 220, 222 or through directengagement with the connection element 270. Thus, as discussed above,the control system 136 operatively connects the shift lever 134 to thegears 120, 122 thereby providing a mechanism for the operator to selecta predetermined gear set.

FIGS. 3 and 4 illustrate additional detail of the control system 136.Specifically, FIG. 3 illustrates a detailed view of the rail selectordamping assembly 260, while FIG. 4 illustrates an exploded view of therail selector damping assembly 310 prior to assembly onto the main shiftrail 210. The exemplary rail selector damping assembly 260, asillustrated in FIG. 3, may be configured having a rail selector 310. Therail selector 310 may include a cylindrical main body 362 with alaterally extending first wing 364 and a laterally extending second wing366. The first and second wings 364, 366 may be offset depending on thespecific application and are not limited to any specific dimension orsize. The wings 364, 366 are illustrated as being mirror images whileprojecting out from the main body 362 of the rail selector 310 along acommon plane. The wings 364, 366 taper from a main body outer surface368 outwardly to an engagement area 370. The exemplary engagement area370 is configured as having a generally flat upper surface 372 and anotched bottom surface 374, the engagement area 370 may includegenerally flat sides 376. The exemplary rail selector 310 configurationallows the main shift rail 210 to engage at least two connectionelements 270 simultaneously. However, the illustrated configuration isnot limiting, and any known shape may be used for the rail selector 310,such that the configuration may transmit movement from the shift lever134 to the at least one shift fork 138, 138′, 138″.

The main body 362 of the rail selector 310 may also include at least onemounting recess 380 extending perpendicularly through at least a portionof one of the first rail selector end 352 and the second rail selectorend 354. The mounting recess 380 may be a cutout for receiving a stoppin 382, which stops the rail selector 310 in a predetermined positionon the main shift rail 210. The mounting recess 380 is configured toprovide clearance around the stop pin 382, which allows the railselector 310 to slide longitudinally a predetermined distance to providea damping effect. The stop pin 382 is slid through an aperture 424 (seeFIG. 4) configured in the main shift rail 210 to engage the mountingrecess 380. The stop pin 382 may be configured to prevent the railselector 310 from rotating inadvertently about the main shift rail 210,thereby providing positive engagement with the connection elements 270.The stop pin 382 is positioned against a bushing or sliding element 412(see FIG. 4) and is retained with at least one position tab 384configured on a tab washer 386. The bushing 412 may be configured tosupport the rail selector 310 and provide a wear element that may allowthe rail selector 310 to move without binding on the shift rail 210. Asillustrated in FIG. 3, the rail selector damping assembly 260 alsoincludes a damping element 388 configured adjacent the tab washer 386and over at least a portion of a tab washer bushing 390. The tab washer386, damping element 388 and tab washer bushing 390 are all retainedlongitudinally on the main shift rail by a retaining element 392. Theretaining element 392 may be of any known shift rail retainingmechanism, such as, but not limited to a snap ring, a pin or other suchelement.

The damping element 388 is illustrated as a resilient spring element.However, the damping element 388 may be constructed of any resilientabsorbing element, such as, but not limited to an elastomer, hydraulicor pneumatic cylinder, silicone, rubber and polymer. Additionally, thetab washer 386, bushing 383, tab washer bushing 390 and retainingelement 392 are not limited to any known material and may be constructedfrom composite, rigid plastic, steel, aluminum, brass and bronze.

With specific reference drawn to FIG. 4, the main shift rail 210 isconfigured with at least two circumferential grooves 422 for receivingthe retaining element 392 and at least two apertures 424, as discussedabove. The exploded view of the rail selector damping assembly 260 showsthe arrangement of how the rail selector damping assembly 260 isconfigured on the main shift rail 210. Thus, the rail selector dampingassembly 260, as discussed above, may include at least one retainingelement 392 slid onto the main shift rail 210 and seated in thecircumferential groove 422. The retaining element 392 is not limited tobeing a removable element and may be a stop that is permanently fixed tothe main shift rail 210. The tab washer bushing 390 is then slid ontothe main shift rail 210 to abut the retaining element 392. Once the tabwasher bushing 390 is put into place the damping element 388 and the tabwasher 386 are slid onto the main shift rail 210, the damping element388 is also slid over the tab washer bushing 390 and abuts a lip on thebushing 390 at one end and abuts the tab washer 386 at the opposing end.Once the tab washer 386 is positioned, the assembled elements areintroduced to a predetermined pressure in the aft direction to compressthe elements a predetermined distance to allow the stop pin 382 to beslid into the aperture 424. Once the stop pin 382 is in place thepressure is removed to allow the elements to expand in the foredirection, thereby applying a predetermined pressure against the stoppin 382 to prevent the stop pin 382 from sliding out of the aperture424. The rail selector 310 may now be slid onto the main shift rail 210and a duplicate set of elements may be configured in an opposing manner.

The rail selector 310 may include an internal sliding surface 410 thatmay include at least one sliding element 412. The sliding element 412 isillustrated as a low friction bushing configured between the railselector inner surface 410 and the main shift rail 210. However, thesliding element 412 is not limited to a bushing and may be ananti-friction coating, a bearing or other such mechanism constructed ofa material such as, but not limited to brass, aluminum or a compositematerial allowing the rail selector 310 to slide longitudinally on themain shift rail 210. When used, the sliding element 412 is slid over themain shift rail 210 to a predetermined location within the rail selector310 to abut the stop pin 382.

As illustrated in FIG. 4 and discussed above, each element is duplicatedboth fore and aft of the rail selector 310 to provide damping in bothdirections. Specifically, the illustrated rail selector damping assembly260 includes a forward stop pin 482 positioned in a forward aperture 426and in a forward mounting recess 480 that is configured on the railselector 310. A forward tab washer 486 having position tabs 484 ispositioned to retain the forward stop pin 482 in place and a forwarddamping element 488 and a forward tab washer bushing 490 are positionedagainst the forward tab washer 486. Once the elements are assembled apredetermined amount of pressure is applied to compress the assemblythereby allowing a forward retaining element 492 to be positioned on themain shift rail 210 and into a forward circumferential groove 428. Onceassembled, the rail selector damping assembly 260 becomes a cohesiveunit with the main shift rail 210 to absorb and limit notchness andother shocks felt at the shift lever 134 by the operator when main shiftrail 210 is moved either for or aft to the shift forks 138, 138′, 138″,synchronizer 140 and the first and second plurality of gears 120, 122,which results in improved shift quality.

Turning now to FIG. 5, a rotating assembly 510 is illustrated. Therotating assembly 510 may include the input shaft 110 operativelyconnected to the output shaft 112 either directly or indirectly throughthe countershaft 118. The rotating assembly 510 may further include thefirst plurality of gears 120, the second plurality of gears 122 and atleast one synchronizer 140. The input shaft 110 includes a first end 512for engaging the prime mover (not illustrated) and a second hollow end514 having an input gear 516 configured on the hollow end 514 and apocket bearing 518 positioned in the hollow end 514. The pocket bearing518 is configured to support the main shaft 116 at a forward end 520 anda bearing 524 supports the main shaft 116 at an aft end 522. The gearedexterior 516 is configured to engage a forward gear 526 configured onthe countershaft 118. The input shaft 110 may be supported in thehousing 124 by at least one bearing 528, while the output shaft 112 maybe supported in the housing 124 by the pocket bearing 518 and thebearing 524. The counter shaft 112 may be separately supported by aforward bearing 530 and an aft bearing 532 configured in the housing124. The bearings 518, 524, 528, 530, 532 are not limited to a specifictype or size, but may include taper, thrust, roller, ball, needle orother type of known bearing.

The countershaft 118 may also include a forward mid-gear 534, an aftmid-gear 536 and an aft gear 538, all of which may be fixedly connectedto the countershaft 118. Thus, the second plurality of gears 122 mayinclude the forward gear 526, the forward mid-gear 534, the aft mid-gear536 and the aft gear 538, the second plurality of gears 122 may beconfigured to transmit torque from the input shaft 110 to the firstplurality of gears 120, which may include a main forward gear 540, amain mid-gear 542 and a main aft gear 544 rotatively attached to themain shaft 116. The gears 540, 542, 544 may include a roller bearing 546configured between the gears 540, 542, 544 and the main shaft 116. Theroller bearing 546 may be a needle bearing that allows the gears 540,542, 544 to rotate about the main shaft 116. Thus, the first pluralityof gears 120 are in rotative alignment with the countershaft 118 and thesecond plurality of gears 122. The number of gears used is not limitedto a specific set, but determined by the size and design of thetransmission. The gears 120, 122 may be of any known gear design and areillustrated as helical gears.

As previously discussed, the plurality of gears 120, 122 transmit torquefrom the input shaft 110 to the yoke 114 configured on the main shaft110 at the rear of the transmission 100. Thus, a torque flow path may bedefined through an interaction between the input gear 516 meshing witheither the forward gear 526, to transmit through the counter shaft 118,or through a gear flange 548 of the synchronizer 140, to transmitdirectly through the main shaft 110. FIG. 5 illustrates that therotating assembly 510 is not limited to the number of synchronizers 140used to transmit that torque, as a forward synchronizer 140′ and an aftsynchronizer 140″ may be included to provide additional torque pathsthrough the counter shaft 118 and the main shaft 116. The synchronizers140′, 140″ engage the main shaft 116 through a splined connection.Specifically, the main shaft 116 includes a forward spline 550 and amid-spline 552 for transmitting the torque from the synchronizers 140′,140″ and through the main shaft 116 to ultimately transmit therotational torque out through the yoke 114. Merely for demonstrationalpurposes, the general synchronizer 140 will be discussed in greaterdetail below.

As further illustrated in FIGS. 5-10, the exemplary synchronizer 140 andits operation will now be discussed in greater detail. The synchronizer140 may be included to provide a smooth transition between the differentshift phases and gear selections within the compound manual transmission100. The synchronizer 140 may be configured to eliminate the “nibble”effect found when changing gears and, which may be felt in the shiftlever 134 by the operator. As illustrated in FIG. 6, the synchronizer140 may include a fixed synchronization hub 610 positioned between twoblockers or synchronizing rings 612. The synchronization hub 610 and thesynchronizing rings 612 are positioned between two separate gear flanges614. The gear flanges 614 and the synchronization hub 610 both includeinternal splines 616, 618. Specifically, the synchronization hub 610includes the internal splines 616, which are configured to engage atleast one of the splines 550, 552 configured on the main shaft 116. Thegear flanges 614 include the internal splines 618, which are configuredto engage with a corresponding spline cut into an edge of the pluralityof gears 120. The splines provide a positive engagement between therotating components to transmit torque, as previously discussed.

Additionally, the synchronization hub 610, synchronization rings 612 andgear flanges 614 all include external gear teeth 620 or other knowndrive feature on an outer surface of each. The external gear teeth 620may be configured to engage corresponding features or internal gearteeth 622 configured on an internal surface of a sliding sleeve 624. Theinternal gear teeth 622 may be provided on an inner diameter 626 of asliding sleeve 624, while a circumferential groove 628 may be configuredin an outer surface 630 of the sliding sleeve 624 for receiving aportion of the shift fork 138. The sliding sleeve internal gear teeth622 may be configured to mesh with and be positioned radially about thesynchronization hub 610, the synchronization rings 612 and the gearflanges 614. The gear teeth 620, 622 may be configured with reducedradial clearance to improve notchness when the sliding sleeve 624 startsto engage the gear flange 614.

The synchronizer 140 may also include a pre-energizer 640, which may beconfigured within the synchronization hub 610 for applying additionalforce during synchronization and engagement. The pre-energizer 640 mayinclude a roller 642, a plunger 644 and a spring 646. The pre-energizer640 may be received in an aperture 648 or cavity that extends radiallyinward at a predetermined distance from an outer radial surface of thehub's external gear teeth 620. The pre-energizer 640 may be assembledwith the spring 646 inserted into the cavity 648, the plunger 644 may beinserted next and then insertion of the roller 642. The pre-energizer640 may be retained through the use of a groove or channel 632configured on the internal diameter 626 of the sliding sleeve 624. Thesynchronizer components may be constructed from known metallicmaterials, such as, but not limited to steel, aluminum, titanium, carbonfiber, plastics or other known materials. The gears may be formed duringthe process of making the components, such as by forming, casting,machining or other known available processes.

FIG. 7 illustrates an exemplary pre-energizer 740. Specifically, thepre-energizer 740 may include an angled roller 742, a plunger 744 and aspring 746. The pre-energizer 740 may be received in an aperture 748 orcavity that extends radially inward at a predetermined distance from anouter radial surface 750 of the hub's external gear teeth 720. Thepre-energizer 740 may be assembled with the spring 746 inserted into thecavity 748, the plunger 744 may be inserted next and then insertion ofthe angled roller 742. The pre-energizer 740 may be retained through theuse of a groove or channel 732 configured on the internal diameter 726of the sliding sleeve 724. The synchronizer components may beconstructed from known metallic materials, such as, but not limited tosteel, aluminum, titanium, carbon fiber, plastics or other knownmaterials. The gears may be formed during the process of making thecomponents, such as by forming, casting, machining or other knownavailable processes.

FIGS. 8A-8C illustrate an exemplary operation sequence where the shiftfork 138 including a shift pad 810, which is positioned within thecircumferential groove 628 when fully assembled. The shift pad 810 isgenerally a plastic or Teflon sleeve that is positioned around a contactsurface on the shift fork 138. The shift pad 810 is utilized to preventfriction from preventing the shift fork 138 from moving the slidingsleeve 624. The shift fork 138 and included shift pad 810 may beconfigured to transmit linear motion from the shift lever 134 to slidingsleeve 624 to allow the synchronizer 140 to select a predetermined gearset, as previously discussed. Specifically, for or aft movement of theshift fork 138 exerts a predetermined force to be transmitted throughthe gear change control system 136 to be applied to the sliding sleeve624. Movement of the sliding sleeve 624 initiates the synchronization ofthe synchronizer 140 and gear engagement. During the synchronizationphase the movement of the sleeve typically results in a high level offorce being developed, further resulting in one of the damping elements388, 488 to be fully compressed. However, the improved detent plunger242 and detent ramp 244 may aid in the reduction of the high level offorce by reducing the force from approximately 29 N to approximately 13N. FIGS. 8B and 8C illustrate this movement of the shift fork 138 to theforward direction, which as the sliding sleeve 624 moves the roller 642,plunger 644 and spring 646 provide resistance, thereby forcing thesynchronizing ring 612 against the targeted gear.

Additionally, the synchronizing rings 612 rotate, due to the friction ofthe rotating assembly 510, until the synchronizing rings 612 meet a wall650 of the fixed synchronization hub 610. At this position a pluralityof engagement chamfers 652 are aligned and the synchronization begins.Once synchronization begins, the compressed damping element 388, 488suddenly releases the compression, thereby allowing the stored energy tomove the damping element 388, 488, which restores the damping element388, 488 to a system kinetics. The released energy speeds up the slidingsleeve 624 to engage the gears while the speed helps to prevent thenibble associated with the engagement of the gears. Once the slidingsleeve 624 is sped up and synchronization progressed, thesynchronization ring 612 and the sliding sleeve 624 are meshed via thechamfers 652 and the external gear teeth 620 on the gear flange 614 arealso aligned via the chamfers 652 and fully engaged by the slidingsleeve 624 as it is advanced toward the gear. Once the internal gearteeth 622 come into contact with the gear flange 614 the external gears620 mesh via the chamfers 652, allowing the sliding sleeve 624 to fullyengage the gear flange 614 and start the transfer of torque through thatspecific gear change.

Referring specifically to FIGS. 9-11, which illustrate and top view ofthe meshing as discussed above. FIG. 9 illustrates the sliding sleeve624 at full engagement with the synchronizing ring 612 as the chamfers652 align the teeth. FIG. 10 illustrates the initial meshing of thesliding sleeve 624 chamfers 652 engaging the chamfers 652 of the gearflange 614 prior to full engagement. FIG. 11 illustrates the fullengagement of the sliding sleeve 624 with the gear flange 614 to createa torque path as previously discussed. Disengagement of the synchronizer140 occurs in the reverse order.

With regard to the processes, systems, methods, heuristics, etc.described herein, it should be understood that, although the steps ofsuch processes, etc. have been described as occurring according to acertain ordered sequence, such processes could be practiced with thedescribed steps performed in an order other than the order describedherein. It further should be understood that certain steps could beperformed simultaneously, that other steps could be added, or thatcertain steps described herein could be omitted. In other words, thedescriptions of processes herein are provided for the purpose ofillustrating certain embodiments, and should in no way be construed soas to limit the claimed invention.

Accordingly, it is to be understood that the above description isintended to be illustrative and not restrictive. Many embodiments andapplications other than the examples provided would be apparent uponreading the above description. The scope of the invention should bedetermined, not with reference to the above description, but shouldinstead be determined with reference to the appended claims, along withthe full scope of equivalents to which such claims are entitled. It isanticipated and intended that future developments will occur in thetechnologies discussed herein, and that the disclosed systems andmethods will be incorporated into such future embodiments. In sum, itshould be understood that the invention is capable of modification andvariation.

All terms used in the claims are intended to be given their broadestreasonable constructions and their ordinary meanings as understood bythose knowledgeable in the technologies described herein unless anexplicit indication to the contrary in made herein. In particular, useof the singular articles such as “a,” “the,” “said,” etc. should be readto recite one or more of the indicated elements unless a claim recitesan explicit limitation to the contrary.

Reference in the specification to “one example,” “an example,” “oneapproach,” or “an application” means that a particular feature,structure, or characteristic described in connection with the example isincluded in at least one example. The phrase “in one example” in variousplaces in the specification does not necessarily refer to the sameexample each time it appears.

The present disclosure has been particularly shown and described withreference to the foregoing illustrations, which are merely illustrativeof the best modes for carrying out the disclosure. It should beunderstood by those skilled in the art that various alternatives to theillustrations of the disclosure described herein may be employed inpracticing the disclosure without departing from the spirit and scope ofthe disclosure as defined in the following claims. It is intended thatthe following claims define the scope of the disclosure and that themethod and apparatus within the scope of these claims and theirequivalents be covered thereby. This description of the disclosureshould be understood to include all novel and non-obvious combinationsof elements described herein, and claims may be presented in this or alater application to any novel and non-obvious combination of theseelements.

Moreover, the foregoing illustrations are illustrative, and no singlefeature or element is essential to all possible combinations that may beclaimed in this or a later application. Therefore, it is intended thatthe invention not be limited to the particular embodiment disclosed asthe best mode contemplated for carrying out this invention, but that theinvention will include all embodiments falling within the scope of theclaims. The invention may be practiced otherwise than is specificallyexplained and illustrated without departing from its spirit or scope.The scope of the invention is limited solely by the following claims.

1-18. (canceled)
 19. A rail selector for use with a compoundtransmission shift mechanism, comprising: a plurality of gearsconfigured on at least one transmission shaft; at least one synchronizerconfigured on at least two of the plurality of gears; a control systemconfigured to engage and position the synchronizer into alignment withat least two gears on the transmission shaft; a damping assembly on thecontrol system and operatively connected to the synchronizer, andconfigured to translate movement of a shift lever through a shift railand through shift forks that are configured to engage the synchronizer;wherein the damping assembly includes a rail selector having laterallyextending wings operatively connected to the shift forks.
 20. The railselector of claim 19, wherein the laterally extending wings include afirst laterally extending wing configured on a first side of the dampingassembly and a second laterally extending wing configured on a secondside of the damping assembly, opposite the first side.
 21. The railselector of claim 19, wherein the control system includes the shift railoperatively connected to the shift forks.
 22. The rail selector of claim19, wherein the control system supports the damping assembly.
 23. Therail selector of claim 19, wherein the control system includes at leastone adjustment mechanism interconnected to the shift rail.
 24. The railselector of claim 23, wherein the at least one adjustment mechanismincludes at least one detent plunger operatively connected to the shiftrail through a detent ramp, the adjustment mechanism configured to atleast one of minimize or eliminate free play when shifting the compoundtransmission.
 25. The rail selector of claim 24, wherein the detent rampincludes an indented center section with outwardly and inwardly slopedramps configured forward and aft of the indented center section.
 26. Therail selector of claim 24, wherein the detent plunger has a length ofapproximately 25 mm to 40 mm.
 27. The rail selector of claim 19, whereinthe damping assembly includes at least one damping element constructedof an absorbing element and configured to absorb movement in at leastone of the plurality of gears.
 28. A transmission shift mechanism,comprising: two or more gears configured on a transmission shaft; asynchronizer configured to engage two of the two or more gears; and acontrol system including shift forks and a main shift rail dampingassembly operatively connected to engage and position the synchronizerinto alignment with the two gears, wherein the damping assembly includesa rail selector having laterally extending wings operatively connectedto the shift forks.
 29. The shift mechanism of claim 28, wherein thelaterally extending wings include a first laterally extending wingconfigured on a first side of the damping assembly and a secondlaterally extending wing configured on a second side of the dampingassembly, opposite the first side.
 30. The shift mechanism of claim 28,wherein the control system supports the damping assembly, and thedamping system is configured to translate movement of a shift leverthrough a shift rail and through the shift forks.
 31. The shiftmechanism of claim 28, wherein the synchronizer including apre-energizer configured with at least one of a roller, a plunger and aspring.
 32. The shift mechanism of claim 31, wherein the synchronizerincludes at least one fixed synchronization hub configured between atleast two synchronizing rings, which are positioned between two gearflanges.
 33. The shift mechanism of claim 28, the synchronizer furthercomprising a synchronization ring and a sliding sleeve configured toengage and mesh each other through a plurality of chamfered gearscorrespondingly configured on each.
 34. The shift mechanism of claim 28,the control system further including an adjustment mechanisminterconnected to at least one of a plurality of shift rails.
 35. Theshift mechanism of claim 34, wherein the adjustment mechanism includes adetent plunger operatively connected to a main shift rail through adetent ramp, the adjustment mechanism configured to at least one ofminimize and eliminate a free play when shifting a compoundtransmission.
 36. The shift mechanism of claim 35, wherein the detentramp includes an indented center section with outwardly and inwardlysloped ramps configured forward and aft of the indented center section.37. The shift mechanism of claim 35, wherein the detent plunger has alength of approximately 30 mm to 35 mm.
 38. The shift mechanism of claim35, wherein the control system is configured to engage and position thesynchronizer into the alignment.